U.S. patent number 9,598,880 [Application Number 14/194,546] was granted by the patent office on 2017-03-21 for lock cylinder including modular plug.
This patent grant is currently assigned to Schlage Lock Company LLC. The grantee listed for this patent is Schlage Lock Company LLC. Invention is credited to Jason Curtis Clifford, Brian Edward Walls, Scott Douglas Welsby.
United States Patent |
9,598,880 |
Walls , et al. |
March 21, 2017 |
Lock cylinder including modular plug
Abstract
In an exemplary embodiment, a plug assembly includes a plug
body, a sidebar, a cover plate, and a plurality of rack pins
positioned in the plug assembly. A first portion of the sidebar is
positioned in the plug and a second portion protrudes beyond the
outer surface of the plug body. The rack pins are configured to
selectably resist and permit radially inward motion of the sidebar.
The cover plate is operable to selectably retain the rack pins
within the plug body.
Inventors: |
Walls; Brian Edward (Colorado
Springs, CO), Clifford; Jason Curtis (Colorado Springs,
CO), Welsby; Scott Douglas (Colorado Springs, CO) |
Applicant: |
Name |
City |
State |
Country |
Type |
Schlage Lock Company LLC |
Indianapolis |
IN |
US |
|
|
Assignee: |
Schlage Lock Company LLC
(Indianapolis, IN)
|
Family
ID: |
54006524 |
Appl.
No.: |
14/194,546 |
Filed: |
February 28, 2014 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20150247344 A1 |
Sep 3, 2015 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E05B
27/0017 (20130101); E05B 9/086 (20130101); E05B
27/0082 (20130101); Y10T 70/7599 (20150401); E05B
27/0007 (20130101); E05B 63/0056 (20130101); E05B
29/0066 (20130101); Y10T 29/49876 (20150115); Y10T
70/7616 (20150401); Y10T 70/7684 (20150401); Y10T
70/752 (20150401) |
Current International
Class: |
E05B
27/04 (20060101); E05B 9/08 (20060101); E05B
27/00 (20060101); E05B 29/04 (20060101); E05B
29/00 (20060101); E05B 63/00 (20060101) |
Field of
Search: |
;70/372,375,385,490,492-496,DIG.3,DIG.15 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
International Search Report and Written Opinion; International
Searching Authority/US; International PCT Application No.
PCT/US15/18052; Jun. 8, 2015; 8 pages. cited by applicant .
Australian Patent Examination Report No. 1; Australian Patent
Office; Australian Patent Application No. 2015222853; Nov. 11,
2016; 3 pages. cited by applicant.
|
Primary Examiner: Gall; Lloyd
Attorney, Agent or Firm: Taft Stettinius & Hollister
LLP
Claims
What is claimed is:
1. An apparatus comprising: a plug assembly, the plug assembly
including: a substantially cylindrical plug body defining a
longitudinal first axis, a transverse second axis, a lateral third
axis, and a central plane including the longitudinal first axis and
the transverse second axis, the plug body comprising: a keyway
extending along the central plane of the plug body, wherein the
keyway is structured to receive a key having a top cut; a plurality
of openings connected to the keyway, wherein each opening is
defined in part by a ledge; and an axial channel formed on the
outer surface of the plug body, and connected to the openings; a
sidebar positioned in the axial channel, the sidebar comprising an
interference member formed on a radially inner side of the sidebar,
and a tapered portion formed on a radially outer side of the
sidebar, wherein the sidebar is biased in a radially outward
direction; a plurality of rack pins positioned in the openings,
each of the rack pins defining a single-piece unitary structure
including a laterally-extending first section positioned at least
partially within the keyway, extending laterally across the central
plane, and structured to engage the top cut of the key, and a
transversely-extending second section extending from the first
section in a first transverse direction and having a contact
surface facing the axial channel, wherein each contact surface
includes a receiving notch having a first lateral depth, wherein
each receiving notch is configured to receive a portion of the
interference member, wherein each of the rack pins is operable in a
first transverse position in which the receiving notch is aligned
with the interference member and a second transverse position in
which the receiving notch is not aligned with the interference
member; wherein each contact surface further comprises a false gate
notch having a second lateral depth less than the first lateral
depth; and wherein each rack pin extends laterally across the
central plane on a single transverse side of the keyway; and a
plurality of biasing members, wherein each of the biasing members
is positioned in one of the openings and urges a corresponding one
of the rack pins in the first transverse direction, and wherein the
biasing members urge the first sections into contact with the
ledges.
2. An apparatus according to claim 1, further comprising a cover
plate rotatably coupled to the plug body, and operable to
selectably expose and cover at least a portion of each opening
while remaining coupled to the plug body; wherein the cover plate
includes an arcuate segment; and wherein the cover plate is
rotatable between an open position in which the openings are
exposed, and a closed position in which the openings are covered by
the arcuate segment of the cover plate.
3. An apparatus according to claim 2, the plug body further
comprising a ridge configured to resist movement of the cover plate
from the closed position.
4. An apparatus according to claim 3, the arcuate segment of the
cover plate comprising a central angle between 180.degree. and
220.degree., inclusive.
5. An apparatus according to claim 4, the arcuate segment of the
cover plate including a channel configured to receive the ridge
when the cover plate is in the open position.
6. An apparatus according to claim 2, wherein the cover plate
further comprises a ring which circumferentially surrounds a
portion of the plug body, and the arcuate segment comprising a
central angle between 15.degree. and 90.degree., inclusive.
7. An apparatus according to claim 1, wherein the second section of
at least one of the rack pins further includes a second receiving
notch configured to receive the portion of the interference
member.
8. An apparatus according to claim 1, further comprising a shell
including a chamber and an axial groove, wherein the plug assembly
is positioned at least partially within the chamber and the tapered
portion is positioned at least partially within the axial
groove.
9. An apparatus according to claim 8, wherein the plug assembly is
rotatable with respect to the shell in an unlocked state in which
the receiving notch of each rack pin is aligned with the
interference member, and is not rotatable with respect to the shell
in a locked state in which the receiving notch of at least one of
the rack pins is not aligned with the interference member.
10. The apparatus of claim 1, wherein the first section is arranged
perpendicular to the second section.
11. An apparatus comprising: a plug defining a longitudinal first
axis, a transverse second axis, a lateral third axis, and a central
plane including the longitudinal first axis and the transverse
second axis, the plug including a keyway extending along the
central plane, a plurality of cavities in communication with the
keyway, and an axial channel in communication with the plurality of
cavities, wherein the keyway is structured to receive a key having
a top cut; a plurality of rack pins, wherein each of the rack pins
is positioned in one of the cavities, wherein each of the rack pins
comprises a single-piece unitary construction including a
laterally-extending first leg and a transversely-extending second
leg extending transversely from the first leg in a first transverse
direction, wherein the first leg is positioned at least partially
in the keyway, extends laterally across the central plane, and is
structured to engage the top cut of the key, and the second leg
includes a contact surface facing the axial channel, wherein each
contact surface includes a receiving notch, and wherein each rack
pin extends laterally across the central plane on a single
transverse side of the keyway; a sidebar seated in the axial
channel, wherein a radially outer side of the sidebar facing away
from the central plane includes a tapered portion, and a radially
inner side of the sidebar facing toward the central plane includes
an interference member sized and configured to be received in the
receiving notch of each rack pin, and wherein the sidebar is biased
in a radially outward direction toward an outer position in which
the tapered portion protrudes beyond an outer surface of the plug;
and a plurality of biasing members, wherein each of the biasing
members is positioned in one of the cavities and urges a
corresponding one of the rack pins in the first transverse
direction; wherein the sidebar is free to move radially inward
toward an inner position when the interference member is aligned
with the receiving notch of each rack pin, and is not free to move
radially inward when the interference member is not aligned with
the receiving notch of at least one of the rack pins; and wherein
each cavity is defined in part by a ledge, and wherein the biasing
members urge the first legs into contact with the ledges.
12. The apparatus of claim 11, wherein each contact surface further
includes a plurality of false gate notches.
13. The apparatus of claim 11, wherein each of the rack pins is
wholly contained within the plug.
14. The apparatus of claim 13, wherein only the sidebar protrudes
beyond the outer surface of the plug.
15. The apparatus of claim 11, further comprising: a shell
including a chamber and an axial groove, wherein the chamber is
generally cylindrical and is defined by an inner surface of the
shell; wherein the plug is rotatably mounted in the chamber, and a
shear line is formed between the outer surface of the plug and the
inner surface of the shell; and wherein, with the sidebar in the
outer position, the sidebar crosses the shear line and the tapered
portion is received in the axial groove.
16. The apparatus of claim 15, wherein each of the rack pins is
wholly contained within the plug and only the sidebar is operable
to cross the shear line.
17. The apparatus of claim 15, wherein the shell is towerless.
18. The apparatus of claim 11, further comprising a cover plate
coupled to the plug, the cover plate retaining the rack pins within
the cavities.
19. The apparatus of claim 18, wherein the cover plate is movably
coupled to the plug and has a closed position in which rack pins
are retained within the cavities and an open position in which the
rack pins are removable from the cavities.
20. The apparatus of claim 19, wherein the open position is a first
angular position, wherein the closed position is a second angular
position, and wherein the cover plate is rotatable between the
first and second angular positions.
21. The apparatus of claim 20, wherein the plug includes a radial
protrusion configured to resist rotation of the cover plate when
the cover plate is in the first angular position.
22. The apparatus of claim 21, wherein the cover plate includes a
hole configured to receive the radial protrusion when the cover
plate is in the first angular position, and wherein the radial
protrusion resists rotation of the cover plate when the cover plate
is in the first angular position.
23. The apparatus of claim 11, wherein each laterally-extending
first leg extends laterally across the central plane from a first
lateral side of the keyway to an opposite second lateral side of
the keyway.
Description
TECHNICAL FIELD
The present invention generally relates to locks, and more
particularly, but not exclusively, to interchangeable core
locks.
BACKGROUND
Lock cylinders, particularly those of the interchangeable core (IC)
variety, have complex part tolerances and pinning to allow the
cylinder to function. Because of the common design, these pinning
complexities can also lead to lower security, which may result in
unintended keys being able to operate the cylinder. The
complexities can also make the pinning process difficult and
laborious. If the pinning is off, the entire assembly must be
emptied, and the user must start over. Furthermore, many
traditional interchangeable core assemblies suffer from a tendency
to "explode" when the plug is removed from the shell. That is to
say, the springs eject the internal components out of the assembly,
losing the pinning placement, and running the risk of damaging,
destroying, or losing components. There is a need for the unique
and inventive apparatuses, systems, and methods disclosed
herein.
SUMMARY
In certain embodiments, a plug assembly includes a plug body, a
sidebar, a cover plate, and a plurality of rack pins positioned in
the plug assembly. A first portion of the sidebar is positioned in
the plug and a second portion protrudes beyond the outer surface of
the plug body. The rack pins are configured to selectably resist
and permit radially inward motion of the sidebar. The cover plate
is operable to selectably retain the rack pins within the plug
body.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective illustration of a lock cylinder according
to an embodiment of the present invention.
FIG. 2 is an exploded view of the lock plug used in the lock
cylinder of FIG. 1.
FIG. 3 is a cross-sectional view of the lock cylinder of FIG. 1 in
a locked state.
FIG. 4 is a cross-sectional view of the lock cylinder of FIG. 1 in
an unlocked state.
FIG. 5 is a perspective illustration of a plug body and cover plate
according to an embodiment of the present invention.
FIG. 5a is a cross-sectional illustration of the plug body and
cover plate illustrated in FIG. 5.
FIG. 6 is a perspective illustration of a rack pin according to an
embodiment of the invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
For the purposes of promoting an understanding of the principles of
the invention, reference will now be made to the embodiments
illustrated in the drawings and specific language will be used to
describe the same. It will nevertheless be understood that no
limitation of the scope of the invention is thereby intended. Any
alterations and further modifications in the described embodiments,
and any further applications of the principles of the invention as
described herein are contemplated as would normally occur to one
skilled in the art to which the invention relates.
As used hereinafter, a reference to the length, height, or width of
an element of a locking cylinder is to be interpreted in light of
the following characterization of the dimensions and definitions
unless specifically noted otherwise. The geometry of the cylinder
defines three mutually orthogonal axes; each dimension is measured
along one of the axes. Length is measured along a first axis
defined as the axial direction of the cylinder. Height is measured
along a second axis, the direction in which the bittings are formed
on a corresponding key, which will be referred to as the vertical
direction. Width is measured along the third axis, which will be
referred to as the horizontal direction. These terms are used for
ease and convenience of description, and are without regard to the
orientation of a system with respect to the environment. For
example, descriptions that reference a vertical direction are
equally applicable when the system is in a horizontal orientation
or an off-axis orientation. Therefore the terms are not to be
construed as limiting the scope of the subject matter herein.
With reference to FIG. 1, an illustrative cylinder 100 includes a
shell 101 and a plug 200. The shell 101 includes a shell body 120.
The shell 101 may further include a tower 103 configured to allow
the cylinder 100 to be installed into an existing cylinder housing
(not shown). In the illustrated embodiment, the tower 103 is
configured such that the cylinder 100 can be installed into a small
format interchangeable core (SFIC) housing. It is also contemplated
that the shell 101 may be of another configuration, such as full
size, mortise, rim, or key-in-knob/lever, or that the shell 101 may
be towerless.
With additional reference to FIGS. 2 and 3, the plug 200 is
positioned partially within a generally cylindrical chamber 122
defined by the shell body 120. The plug 200 includes a plug body
210, a cover plate 220, a sidebar 230, and a plurality of rack pins
240. The shell body 120 also includes an axial groove 123
configured to receive a portion of the sidebar 230.
The plug body 210 includes a faceplate 211, a recessed portion 212,
an axial channel 213, a plurality of cavities 214, and a keyway 219
configured to receive a key (not illustrated). The recessed portion
212 is an arcuate portion of the plug body 210 configured to
receive the cover plate 220; the recessed portion 212 comprises a
recess radius R212 which is less than the plug body radius R210.
The channel 213 extends in the axial direction of the plug body
210, and is configured to the receive the sidebar 230 and biasing
members 203. Each of the cavities 214 is configured to receive a
rack pin 240 and a biasing member 204, and is connected to the
recessed portion 212, the axial channel 213, and the keyway 219.
Upon insertion of a key into the keyway 219, each rack pin 240 can
engage both the sidebar 230 and the key.
The cover plate 220 is an arcuate plate including terminal surfaces
221 and slots 225. The inner radius of the cover plate 220
corresponds to the recess radius R212, and the outer radius
corresponds to the plug body radius R210. The cover plate 220 is
configured to be received in the recess 212 such that the cover
plate 220 is rotatably coupled to the plug body 210. In the
illustrated form, the cover plate 220 comprises an arc having a
central angle .theta.220 greater than 180.degree., and the terminal
surfaces 221 are separated by a distance less than the diameter
across the recess 212. While the exemplary cover plate 220
comprises an arc having a central angle .theta.220 of about
200.degree., other central angles are also contemplated. In certain
embodiments, a cover plate may have a central angle between
185.degree. and 315.degree., between 190.degree. and 280.degree.,
or between 195.degree. and 220.degree.. In other embodiments, the
arc may have a central angle less than 180.degree.; an exemplary
form of one such cover plate is described below with reference to
FIG. 5.
The illustrated cover plate 220 is slightly flexible, such that
separating the terminal surfaces 221 by a distance corresponding to
the diameter across the recess 212 does not cause permanent
deformation of the cover plate 220. This allows the cover plate 220
to be installed into the recess 212 by pressing the cover plate 220
into the recess 212 in a snap-fit manner. When installed in the
recess 212, the cover plate 220 is rotatably clamped to the plug
body 210; in other words, the cover plate 220 can rotate about the
longitudinal axis of the plug body 210 within the confines of the
recess 212, but movement in the radial or axial direction of the
plug body 210 is substantially prevented.
While the exemplary cover plate 220 is installed in the
above-described snap-fit manner, it is also contemplated that the
cover plate 220 may be installed by sliding the cover plate into
the recess 212, for example, prior to affixing the faceplate 211.
Alternatively, the recess 212 may extend to the end of the plug
body 210 opposite the faceplate 211, and the cover plate 220 may be
slid into the recess 212 and retained therein by a ridge or
retainer (not illustrated).
The cover plate 220 is rotatable about the longitudinal axis of the
plug body 210 between a closed position (FIG. 3) and an open
position, and is capable of rotating between the closed position
and the open position without being decoupled from the plug body
220. In the closed position, the cavities 214 are covered by the
cover plate 220, and the rack pins 240 and the biasing members 204
are retained in the cavities 214. When the plug 200 is removed from
the shell 101, the closed cover plate thus prevents the cylinder
100 from "exploding" without requiring the use of a plug follower.
In the open position of the cover plate 220, the cavities 214 are
exposed, and the rack pins 240 can be inserted into or removed from
the cavities 214. This allows the plug 200 to be completely
assembled prior to being installed in a shell appropriate for the
lock type. The modular nature of the plug 200 enables installation
of the same plug in any of a variety of shells corresponding to
different lock types.
Rotation of the cover plate 220 from the open or closed position is
resisted by a ridge 215 formed on the plug body 210. When the cover
plate 220 is in the closed position, the ridge 215 contacts one of
the terminal surfaces 221. When the cover plate 220 is in the open
position, the ridge 215 is positioned in the slot 225. The distance
by which the ridge 215 protrudes from the surface of the recessed
portion 212 is great enough to resist incidental rotation of the
cover plate 220, but small enough that intentional rotation is not
prevented. In other words, the ridge 215 prevents rotation of the
cover plate 220 in the absence of a threshold torque being applied.
In certain embodiments, the ridge 215 may be a bump having a small
length in the axial direction; in other forms, the ridge 215 may
extend in the axial direction of the plug body 210. The
cross-section of the ridge 215 may be curvilinear, rectilinear, or
a combination thereof. In certain embodiments, the plug body 210
may include a plurality of ridges, or may not include a ridge. For
example, one or more ridges may be formed on the cover plate 220,
and correspondingly shaped grooves may be formed on the plug body
210.
The sidebar 230 is positioned in the axial channel 213, and is
biased radially outward by the biasing members 203. The sidebar 230
includes a body portion 231, a tapered portion 232 on the radially
outward side of body portion 231, and an interference member
(illustrated as protrusion 233) on the radially inward side of the
body portion 231. While the exemplary interference member is a
single contiguous protrusion 233, the interference member may
comprise a plurality of discrete protrusions in certain
embodiments.
The height of the body portion 231 corresponds to the height of the
channel 213, such that movement of the sidebar 230 is substantially
confined to the radial direction of the plug body 210. In the
illustrated form, the height of the protrusion 233 is less than the
height of the body portion 231, although it is also contemplated
that the body portion 231 and the protrusion 233 may be the same
height or substantially the same height. Furthermore, while the
tapered portion 232 is depicted as having a substantially
rectilinear cross-section, it is also contemplated that the tapered
portion 232 may comprise a curvilinear profile.
The rack pins 240 are positioned in the cavities 214 along with the
biasing members 204, and each rack pin 240 includes a first leg 241
and a second leg 242. When the cover plate 220 is in the closed
position, the biasing members 204 urge the rack pins 240 toward the
keyway 219, such that each of the first legs 241 engages a ledge
217. In the illustrated embodiment, the first leg 241 is
perpendicular to the second leg 242, although other configurations
are contemplated. For example, in certain embodiments, the legs
241, 242 may be substantially perpendicular, or may be offset by an
oblique angle. In the illustrated embodiment, the second leg 242
extends from the end of the first leg 241 in only a single
direction, and the rack pin 240 can thus be considered an L-shaped
rack pin.
The first leg 241 is positioned at least partially in the keyway
219, and is configured to travel along the top cut of a key. The
first leg 241 may include a tapered bottom surface (for example,
angled or curved) to facilitate such travel. When the key is
inserted into the keyway 219, each of the rack pins 240 moves in a
direction substantially perpendicular to the direction of key
insertion as the first leg 241 travels along the top cut of the
key. Due to the fact that the biasing members 204 urge the first
legs 241 into contact with the key, the position of each of the
rack pins 240 corresponds to the root depth of the key at the point
of contact. If a rack pin 240 is blocked from moving in the
necessary direction, the key cannot be inserted, due to the
interference between the blocked rack pin 240 and the teeth of the
key; this is equally true for extraction of the key.
The second leg 242 includes at least one notch 243 configured to
receive a portion of the protrusion 233. One or more of the rack
pins 240 may include more than one notch 243, such that the plug
200 can be master-keyed. When the notch 243 is aligned with the
protrusion 233, protrusion 233 can enter the notch 243, and the
rack pin 240 does not prevent the sidebar 230 from moving radially
inward. When the notch 243 is misaligned with the protrusion 233,
the protrusion 233 engages a contact surface 244 of the second leg
242, thereby preventing the sidebar 230 from moving radially
inward.
The alignment or misalignment of the notch 243 and the protrusion
233 is determined by the vertical position of the rack pin 240,
which in turn depends upon the root depth of an inserted key at the
corresponding bitting position. When a proper key is inserted, each
rack pin 240 has a notch 243 aligned with the protrusion 233. This
defines an unlocked state of the plug 200, in which the sidebar 230
is free to move radially inward. When a proper key is not inserted,
at least one of the rack pins 240 does not have a notch 243 aligned
with the protrusion 233. This defines a locked state of the plug
200, in which the sidebar 230 is prevented from moving radially
inward.
With additional reference to FIG. 4, the operation of the cylinder
100 will now be described. FIG. 3 illustrates the plug 200 in a
home position, wherein the biasing members 203 urge the sidebar to
an extended position in which at least part of the tapered portion
232 is positioned in the groove 123. The plug 200 is also in the
locked state, as the protrusion 233 is not aligned with the notch
243, and the interaction of the protrusion 233 and the contact
surface 244 prevents the sidebar 230 from moving radially inward.
In other words, the rack pin 240 retains the sidebar 230 in the
extended position. Due to the fact that the sidebar 230 cannot move
radially inward, the surfaces of the groove 123 interfere with the
tapered portion 232, preventing rotation of the plug 200 with
respect to the shell 101. The sidebar 230 is the only element that
crosses the shear line of the cylinder 100, as the rack pins 240
are contained within the plug 200 by the cover plate 230.
As described above, when a proper key is inserted, each rack pin
240 has a notch 243 aligned with the protrusion 233, and the
sidebar 230 is free to move radially inward. In this unlocked
state, rotation of the plug 200 causes a surface of the groove 123
to interact with the tapered portion 232, thereby urging the
sidebar 230 radially inward. That is to say, the surfaces of the
groove 123 and the tapered portion 232 are cam surfaces configured
to urge the sidebar 230 radially inward upon rotation of the plug
200. Once the plug 200 has been sufficiently rotated, the sidebar
230 is in a retracted position (FIG. 4), in which the protrusion
233 is received in the notch 243. In this rotated position of the
plug 200, the tapered portion 232 is in contact with an inner
surface of the shell 101, retaining the protrusion 232 within the
notches 243. As noted above, in order for the key to be inserted
into or extracted from the keyway 219, the rack pins 240 must be
free to travel. In the rotated position of the plug 200, however,
such travel is blocked, due to the protrusion 232 being retained
within the notch 243. As such, when the plug 200 is in the rotated
position, the key cannot be extracted.
As the plug 200 is rotated back to the home position, the biasing
members 203 urge the sidebar 230 radially outward into the groove
123. The protrusion 233 is thus removed from the notch 243, and the
rack pins 240 again become free to travel, permitting extraction of
the key. Once the key is extracted, the biasing members 204 urge
the rack pins 240 to their initial positions (FIG. 3), in which the
protrusion 233 is misaligned with the recesses 243, and the plug
200 is in the locked state.
With continued reference to FIGS. 1-4, the exemplary cylinder 100
also includes a control member 130. The control member 130 is
rotatable with respect to the shell 101, and includes a retaining
lug 132 configured to engage a corresponding notch in the cylinder
housing. In a first angular position of the control member 130
(FIG. 1), the retaining lug 132 radially protrudes from the shell
101 into the cylinder housing notch, preventing the cylinder 100
from being removed from the cylinder housing. When the control
member 130 is rotated to a second angular position, the retaining
lug 132 is positioned within the tower 103, and the cylinder 100
can be removed from the cylinder housing.
As best seen in FIG. 2, the plug body 210 may further include a
control pin cavity 217, and the cover plate 220 may further include
an opening 227. The control pin cavity 217 and the opening 227 are
positioned such that, when the cover plate 220 is in the closed
position, the opening 227 is aligned with the control pin cavity
217. When the plug 200 is in the home position (FIG. 3) and the
cover plate 220 is in the closed position, the control pin cavity
217 and the opening 227 are aligned with a correspondingly-sized
cavity formed in the control member 130. The control pin cavity 217
has disposed therein a control pin (not illustrated) operable in a
first position in which a portion of the control pin extends into
the control member cavity, and a second position in which the
control pin does not extend into the control member cavity. The
control pin is configured to interact with a feature of a change
key, such that the control pin is in the first position when a
proper change key is inserted in the keyway 219, and is in the
second position when a proper change key is not so inserted.
When a proper change key is inserted, the plug 200 is in the
unlocked state, and the control pin is in the first position. In
this state, rotation of the plug 210 also causes rotation of the
control member 130, due to the control pin extending into the
control member cavity. Once the control member 130 is in the second
angular position, the control lug 132 is positioned within the
tower 103, and the cylinder 100 can be removed from the cylinder
housing. In certain embodiments, the control pin may interact with
sidemilling on the change key, such that the position of the
control pin is independent of the key top cut, providing more
security and control.
Once the cylinder 100 has been removed from the cylinder housing,
the plug 200 can be removed from the shell 101 for re-pinning. In
order to re-pin the plug 200, a user rotates the cover plate 220
from the closed position to the open position, where it may be
retained by the ridge 215. The user removes at least some of the
springs 204 and the rack pins 240 from the cavities 214. The user
may simply rearrange some of the rack pins 240 (i.e. by placing at
least some of the rack pins 240 in different cavities 214), may
replace one or more of the rack pins 240 with new rack pins, or a
combination thereof. The springs 204 are then put back into the
cavities, and the cover plate 220 is rotated back to the closed
position, where it is retained by the ridge 215. The user next
inserts the plug 200 into the shell 101 (or another shell of the
same, similar, or different format), inserts the cylinder 100 into
the cylinder housing, and rotates the plug 200 and the control
member 130 to a position in which the retaining lug 132 prevents
removal of the cylinder 100 from the cylinder housing. Because the
plug 200 is self-contained, there is no need to position springs
and driving pins in the shell 101 during assembly, reducing the
time and complexity of the pinning process.
FIGS. 5 and 5a illustrate a second exemplary plug body 510 and a
cover 520. The plug body 510 is substantially similar to the plug
body 210, and includes a recessed portion 512 having a radius less
than that of the remainder of the plug body 510, and a plurality of
cavities 514 configured to receive rack pins (not illustrated). The
recessed portion 512 is an arcuate portion of the plug body 510;
the central angle of the arc defined by the recessed portion is
hereinafter referred to as the recess angle .alpha..
The cover 520 includes a cover plate 522 positioned in the recessed
portion 512, and keepers 524 which rotatably couple the cover 520
to the plug body 510. The cover plate 522 is arcuate in geometry,
and comprises a central angle which is hereinafter referred to as
the cover plate angle .beta.. The cover plate 522 comprises an
inner radius corresponding to the radius of the recessed portion
512, and an outer radius corresponding to the outer radius of the
plug body 510. The keepers 524 may be positioned in a
circumferential groove 519 on the plug body 510. In the illustrated
embodiment, the arcuate keepers 524 comprise a central angle
.theta.524 of greater than about 190.degree. and less than about
300.degree., and are snap-fit into the circumferential groove 519
in a manner similar to that described above with reference to the
cover plate 220. In other embodiments, the keepers 524 may comprise
a greater central angle, which may be up to 360.degree.. In other
words, the keepers 524 may be complete circles circumferentially
surrounding a portion of the plug body 510. In still further
embodiments, the keepers 524 may comprise a lesser central angle,
and may be positioned in grooves on the faceplate and/or the end of
the plug 510 opposite the faceplate.
The cover plate 522 is rotatable about the longitudinal axis of the
plug body 510 along the recess 512. In an open position of the
cover plate 522, the cavities 514 are exposed, and rack pins and
biasing members (not illustrated) can be inserted or removed from
the cavities 514. In a closed position of the cover plate 520, the
cavities 514 are covered, and the pins and springs are retained
within the cavities 514. In the illustrated embodiment, the plug
body 510 includes two ridges 515 which extend along the axial
direction of the plug body 510, and are configured to resist
rotation of the cover plate 522 from the closed position. The
ridges 515 are substantially similar to the ridge 215, and the
descriptions of the illustrated and alternative features of the
ridge 215 are equally applicable to the ridges 515.
In the illustrated embodiment, the recess angle .alpha. is slightly
greater than twice the cover plate angle .beta., and the ridges 515
bisect the recessed portion 512 into first and second recessed
sections, the angular span of each corresponding to the cover plate
angle .beta.. For example, if the cover plate angle .theta. is
30.degree., the recess angle .alpha. may be between about
62.degree. and about 70.degree.. As such, the cover plate 522 can
be stably positioned in either the open position or the closed
position, and the ridges 515 will retain the cover plate 522 in the
selected position until the user rotates the cover plate 522 to the
new position. In this manner, the ridges 515 facilitate the pinning
process, and ensure that the cover plate 522 remains in the closed
position when installed into a shell (such as the
previously-described shell 101).
While the cover plate 522 comprises an are having a central angle
of about 30.degree., other central angles are contemplated. In
certain embodiments, the cover plate 522 may comprise an are having
a central angle between 10.degree. and 180.degree., between
15.degree. and 90.degree., or between 20.degree. and 45.degree.. In
certain embodiments, the recess angle .alpha. may be more than
twice the cover plate angle .beta.. In further embodiments, the
recess angle .alpha. may be less than twice the cover plate angle
.beta., in which case the cover plate 522 may include slots
configured engage the ridges 515 when the cover plate 522 is in the
open or closed position in a manner similar to that described with
reference to the slots 225. Furthermore, in certain embodiments,
the ridges 515 may not bisect the recessed portion 512.
A common form of picking locks includes applying torque to a lock
plug, and adjusting the position of a pin until the resistive force
provided by the pin changes. This change in resistive force is
interpreted by the picker as an indication that the pin or tumbler
is aligned with the shear line, and will no longer prevent rotation
of the plug. The process is repeated until each of the pins is in
the unlocking position, and the plug can be rotated. To combat such
picking, certain embodiments of the invention may include
anti-tampering features; an exemplary form of such anti-tampering
features will now be described with reference to FIGS. 2 and 6.
FIG. 6 depicts an alternative form of rack pin 640 which may be
utilized in certain embodiments of the invention. The rack pin 640
is substantially similar to the previously-described rack pins 240,
and similar reference characters are used to denote similar
features. In the interest of conciseness, the following description
focuses primarily on features which are different than those
previously described with reference to the rack pins 240.
In the present form of the rack pin 640, the second leg 642
includes upper and lower portions extending from the first leg 641
in opposite directions, defining the rack pin 640 as a T-shaped
rack pin. The upper and lower portions may engage the walls of the
rack pin cavities 214, substantially constraining motion of the
rack pin 640 to an axis parallel to the second leg 642 during key
insertion.
The second leg 642 also includes a plurality of false gate notches
645 formed in the contact surface 644. If an unauthorized person
attempts to pick the lock using the above-described method, the
torque provided by the picker urges the sidebar 230 radially
inward, and the protrusion 233 comes into contact with the contact
surface 644. When the picker adjusts the position of the rack pin
640 with a picking tool, the sidebar protrusion 233 engages one of
the false gate notches 645, changing the resistive force provided
by the rack pin 640. The picker will falsely interpret this change
in resistive force as indication that the rack pin 640 is in an
unlocking position. Because the rack pin 640 is actually in the
locking position, however, the engagement of the sidebar protrusion
233 and the contact surface 644 prevents rotation of the plug 200,
as described above.
The first leg 641 also includes features which differ from the
depictions of the first leg 241. For example, the first leg 641
includes a tapered portion 646 configured to facilitate travel of
the rack pin 640 along the top cut of the key during key insertion.
The tapered portion 646 may have a shape corresponding to the
bitting length and tooth angle which are standard for a particular
form of key. In such cases, the tapered portion 646 may be flush
with adjacent teeth when the key is fully inserted, such that the
rack pin 640 substantially prevents movement of the key in either
direction when the plug 200 is in the rotated position. The first
leg 641 may also include a protrusion 647 configured to be received
in one end of a spring 204, to prevent the spring 204 from sliding
out of engagement with the first leg 641 during operation.
While the figures depict only the L-shaped rack pin 240 and the
T-shaped rack pin 640, other forms of rack pin are contemplated. In
certain embodiments, one or more of the rack pins may include a
third leg (not illustrated) on the opposite side of the first leg
from the second leg. In such embodiments, the second and third leg
may each extend in only one direction (U-shaped), may both extend
in opposing directions (H-shaped), or one of the vertical legs may
extend in both directions and the other may extend in only one
direction (h-shaped). In such embodiments, the third leg may
include sidebar-receiving notches, and the plug 200 may include a
second sidebar similar to the sidebar 230, which prevents rotation
of the plug 200 when the protrusion of the second sidebar is not
aligned with the notches in the third leg.
While the invention has been illustrated and described in detail in
the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the preferred embodiments have been
shown and described and that all changes and modifications that
come within the spirit of the inventions are desired to be
protected. It should be understood that while the use of words such
as preferable, preferably, preferred or more preferred utilized in
the description above indicate that the feature so described may be
more desirable, it nonetheless may not be necessary and embodiments
lacking the same may be contemplated as within the scope of the
invention, the scope being defined by the claims that follow. In
reading the claims, it is intended that when words such as "a,"
"an," "at least one," or "at least one portion" are used there is
no intention to limit the claim to only one item unless
specifically stated to the contrary in the claim. When the language
"at least a portion" and/or "a portion" is used the item can
include a portion and/or the entire item unless specifically stated
to the contrary.
* * * * *